6S & LEAN MANUFACTURING
“Embedding Discipline, Efficiency, and Continuous Improvement Across Manufacturing Operations”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 07 – 11 Sep 2026 | Dubai, UAE | USD 3495 per delegate |
Course Introduction
Lean manufacturing is about doing more with less—less waste, fewer delays, and minimal resource consumption—while maximizing customer value and product quality. The 6S methodology (Sort, Set in order, Shine, Standardize, Sustain, Safety) forms the cultural foundation for a disciplined, high-performance manufacturing environment.
This intensive five-day training provides a practical, hands-on framework for applying 6S and lean manufacturing principles across operations. Participants will learn to map value streams, reduce waste, optimize layouts, and build a culture of continuous improvement that drives productivity, safety, and employee engagement.
Course Objectives
By the end of this course, participants will be able to:
- Implement the 6S methodology to improve workplace discipline and safety.
- Apply lean principles to eliminate waste and improve manufacturing flow.
- Analyze value streams and identify non-value-adding activities.
- Develop visual management systems and standardized work processes.
- Lead kaizen events and continuous improvement projects.
- Foster a lean culture focused on quality, consistency, and employee involvement.
Key Benefits of Attending
- Create clean, organized, and safe workspaces using 6S practices.
- Reduce production downtime, excess inventory, and rework.
- Boost efficiency through layout redesign and process improvement.
- Learn how to involve frontline teams in lean thinking and waste reduction.
- Drive sustainable productivity through practical, daily improvement habits.
Intended Audience
This program is designed for:
- Production supervisors, team leaders, and manufacturing engineers
- Continuous improvement and lean coordinators
- Quality, safety, and operations professionals
- Facility managers and maintenance planners
- Anyone responsible for shop floor discipline and efficiency
Individual Benefits
Key competencies that will be developed include:
- Workplace organization and process discipline
- Value stream analysis and waste identification
- Root cause analysis and visual problem solving
- Team leadership in lean initiatives
- Application of 6S audits and improvement cycles
Organization Benefits
Upon completing the training course, participants will demonstrate:
- Cleaner, safer, and more efficient production environments
- Reduced waste, downtime, and process variability
- Higher employee ownership and involvement in improvement
- More effective equipment utilization and layout design
- Stronger alignment with lean manufacturing principles
Instructional Methdology
The course follows a blended learning approach combining theory with practical application:
- Lectures – 6S and lean frameworks, tools, and case examples
- Workshops – Simulation of kaizen and value stream mapping
- Templates – Audit checklists, standard work forms, and layout diagrams
- Visual Tools – 6S visuals, andon boards, control charts
- Peer Learning – Group discussions, problem solving, and benchmarking
- On-Site Application – Real-world implementation strategy development
Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Introduction to Lean & 6S Foundations
- Module 1: Lean Thinking and Waste Elimination (07:30 – 09:30)
- Origins and philosophy of lean
- 8 types of waste (TIMWOODS)
- Role of 6S in lean transformation
- Module 2: Overview of 6S Principles (09:45 – 11:15)
- Sort, Set in order, Shine, Standardize, Sustain, Safety
- Creating visual control and organization
- Benefits of 6S for safety, morale, and performance
- Module 3: Starting a 6S Program (11:30 – 01:00)
- Leadership roles and responsibilities
- Selecting pilot areas and setting targets
- Building checklists and 6S audit forms
- Module 4: Exercise – 6S Workplace Simulation (02:00 – 03:30)
- Hands-on workspace setup and visual organization simulation
Day 2: Waste Elimination and Value Stream Mapping
- Module 5: Identifying Value vs. Waste (07:30 – 09:30)
- Defining value in customer terms
- Examples of common waste in manufacturing
- Gemba walk best practices
- Module 6: Value Stream Mapping (09:45 – 11:15)
- Mapping current-state process flows
- Identifying delays, bottlenecks, and non-value steps
- Building future-state improvement targets
- Module 7: Lean Metrics and Visual Control (11:30 – 01:00)
- KPIs for lean performance
- Visual tools: andon, boards, takt time, flowcharts
- Building effective daily management systems
- Module 8: Workshop – Value Stream Mapping (02:00 – 03:30)
- Group activity: mapping and analyzing a manufacturing process
Day 3: Standardization and Layout Efficiency
- Module 9: Standard Work and Best Practices (07:30 – 09:30)
- Why standardization matters in lean
- Documenting procedures for consistency
- Updating and improving standard work
- Module 10: Visual Management Systems (09:45 – 11:15)
- Using visuals to manage production flow and quality
- Floor marking, color coding, and kanban
- Operator self-management tools
- Module 11: Plant Layout and Flow Efficiency (11:30 – 01:00)
- Cellular layout and one-piece flow
- Equipment positioning and motion economy
- Minimizing transport and over-processing
- Module 12: Simulation – Layout Redesign Challenge (02:00 – 03:30)
- Rework a current layout for improved space and movement efficiency
Day 4: Team Engagement and Continuous Improvement
- Module 13: Kaizen and Daily Improvement (07:30 – 09:30)
- What is kaizen and how to implement it
- Empowering teams to solve problems
- Kaizen events vs. daily improvement habits
- Module 14: Root Cause Analysis and Problem Solving (09:45 – 11:15)
- 5 Whys, fishbone diagrams, and PDCA
- Problem containment and corrective action
- Tracking fixes with effectiveness reviews
- Module 15: Building a Lean Culture (11:30 – 01:00)
- Leadership visibility and Gemba leadership
- Recognition and motivation for lean participation
- Training and cross-functional teamwork
- Module 16: Workshop – Kaizen Idea Development (02:00 – 03:30)
- Develop and present a kaizen idea proposal with ROI projection
Day 5: Auditing, Safety & Sustainability
- Module 17: 6S Audits and Visual Discipline (07:30 – 09:30)
- Creating audit schedules and scorecards
- Scoring criteria and self-audits
- Maintaining long-term discipline
- Module 18: Safety Integration into Lean (09:45 – 11:15)
- Identifying safety hazards in lean setups
- 6S role in accident prevention
- Safety communication and incident response
- Module 19: Sustainability and Lean Maturity (11:30 – 01:00)
- Sustaining results beyond the project
- Lean maturity models and assessments
- Continuous coaching and leadership engagement
- Module 20: Final Presentation and Improvement Plan (02:00 – 03:30)
- Team presentations on lean improvement roadmaps
- Certification briefing and close-out
Certification
Participants who complete the program will receive a Certificate of Completion in 6S & Lean Manufacturing, recognizing their capability to implement workplace discipline, reduce waste, and lead continuous improvement efforts within manufacturing operations.